Method for peeling the interlayer of a two-sided adhesive tape

ABSTRACT

A peeling apparatus of a separator of a two-sided adhesive tape includes a table for mounting and fixing an element having on a surface a two-side adhesive tape having a separator adhered on the top surface, a feeder for feeding a peeling tape having an adhesive surface, a main roller for pressing the adhesive surface of the peeling tape to the separator, thereby adhering the peeling tape to the separator, and a positioner for positioning the table by relatively moving the table to the main roller. The separator adhered to the peeling tape is peeled off from the two-side adhesive tape by the movement of the table, and a feed reel for taking up the peeling tape. The separator peeled off from the two-side adhesive tape is taken up by the feed reel together with the peeling tape.

BACKGROUND OF THE INVENTION

The present invention relates to an apparatus and method for peeling theinterlayer, or separator, from the top surface of a two-sided adhesivetape. More specifically, the peeling apparatus of the present inventionmay be used to separate an interlayer from the top surface of ananisotropic conductive film where the bottom surface of the anisotropicconductive film is adhered to a panel member, for example a liquidcrystal display element.

In the prior art it is known to utilize anisotropic conductive filmswhen bonding an integrated driver circuit to the electrodes of a panelelement such as a liquid crystal display. These anisotropic conductivefilms generally comprise two-sided adhesive tapes which have aninterlayer film or separator applied on both sides, or alternatelyprotecting at least one of the adhesive surfaces. These anisotropicconductive films are then wound on a feed reel.

For example, prior art processes for mounting an integrated drivercircuit on panel element electrodes by using an anisotropic conductivefilm or tape having both adhesive surfaces protected by an interlayerhave generally comprised the following steps:

(1) A bottom interlayer or separator on the bottom surface of the tapeis peeled off, leaving the bottom surface of the anisotropic conductivefilm exposed;

(2) The tape is cut to a specific size;

(3) The exposed bottom surface of the sized anisotropic conductive filmis adhered to an electrode on a panel element;

(4) A top interlayer or separator is peeled off from the top surface ofthe tape, leaving the top surface of the anisotropic conductive filmexposed; and

(5) The integrated driver circuit is adhered on the exposed top surfaceof the anisotropic conductive film.

In the prior art, the steps involving peeling the top interlayer orseparator away from the anisotropic conductive film in step (4) havebeen performed manually due to the absence of a viable alternativeprocedure. Because this step is performed manually, the manufacture ofdevices such as described above suffers due to the lack of efficiencyand precision inherent in such manual processes.

As can be readily recognized, the prior art lacks the advantages of aprocedure which allows performing step (4) of peeling the interlayeraway from the anisotropic film in an efficient and precise fashion.Also, the prior art fails to lend itself to any degree of automation dueto the manual nature of peeling the separator from the conductive film.

The present invention solves these problems by providing an apparatusand method for efficiently and precisely peeling the separator from thetop surface of the two-side adhesive tape such as anisotropic conductivefilm in step (4) without the use of manual labor. By avoiding the use ofmanual labor, it is possible to avoid the loss of time and money in themanufacture of devices which require the use of two-sided anisotropicfilms.

SUMMARY OF THE INVENTION

According to the present invention, an apparatus for peeling aninterlayer of a two-sided adhesive tape to leave a side of the two-sidedadhesive tape exposed is provided comprising: mounting and fixing meansfor mounting and fixing a panel element in a position exposing theinterlayer of the two-sided adhesive tape; feeding means for feeding apeeling tape having an adhesive surface; contacting means for contactingthe adhesive surface of the peeling tape to the interlayer of the panelmember on the mounting and fixing means to adhere the peeling tape tothe interlayer; positioning means for positioning the mounting andfixing means relative to the two-sided adhesive tape by moving themounting and fixing means in proximity of the contacting means; anduptake means for taking up the peeling tape subsequent to the peelingtape being contacted with the interlayer.

A preferred embodiment of the invention comprises an apparatus forpeeling an interlayer of a two-sided adhesive tape to leave an adhesivesurface of the two-sided adhesive tape exposed comprising: a table whichmounts and fixes a panel element in a position exposing the interlayerof the two-sided adhesive tape; a first peeling tape drive means forfeeding a peeling tape having an adhesive surface; a roller which forcesthe adhesive surface of the peeling tape into contact and adhering tothe interlayer of the panel member mounted on the table; a table drivemeans for positioning the table relative to the two-sided adhesive tapeby moving the table into proximity with the roller; and a second peelingtape drive means for taking up the peeling tape subsequent to thepeeling tape being contacted with the interlayer.

Also, according to the present invention, a method of peeling theinterlayer of a two-sided adhesive tape is provided comprising a methodof peeling an interlayer of a two-sided adhesive tape on an electrode ofa panel element comprising: pressing an adhesive surface of a peelingtape to the end portion of the interlayer adhered on the top surface ofthe two-sided adhesive tape adhered on the panel element with a mainroller; and moving the main roller toward the opposite end portion ofthe interlayer while simultaneously pressing the main roller against theadhesive surface of the peeling tape against the interlayer.

As pointed out in detail below, the present invention provides importantadvantages. For example, by using the present invention in place ofmanual labor in the manufacture of devices incorporating integrateddriver circuits, it is possible to save both time and money and userobotic and other automated devices. Additionally, it is possible tointroduce a level of precision and control into the manufacturingprocess not easily obtained by manual labor.

The invention itself, together with further objects and attendantadvantages, will best be understood by reference to the followingdetailed description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a peeling apparatus according to thepresent invention.

FIG. 2 is a front view of a peeling unit of a peeling apparatusaccording to the present invention.

FIG. 3 is a rear view of a peeling unit of the peeling apparatusaccording to the present invention.

FIG. 4 is a cross-sectional view along line A--A of the peeling unitshown in FIG. 2.

FIG. 5 is a cross-sectional view along line B--B of the peeling unitshown in FIG. 2.

FIG. 6 is a magnified sectional view of part C in FIG. 4.

FIG. 7 is an illustration of the peeling apparatus of the presentinvention as the peeling unit contacts the interlayer of the anisotropicfilm.

FIG. 8 is an illustration of the peeling apparatus of the presentinvention as the interlayer is peeled away from the anisotropicconductive film.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, FIG. 1 illustrates a perspective view of apreferred embodiment of the peeling apparatus 110 according to thepresent invention. A panel element 1, for example a liquid crystaldisplay, is mounted on a table 200, moveable in the X-direction. Thetable 200 is driven by a motor 217. Underneath the table 200 is a table201, moveable in the Y-direction, which is driven by a motor 218. Thepanel element 1 has adhered thereon an anisotropic conductive film, ortape, 2 which includes an interlayer 3 on the top surface. The bottomsurface of the anisotropic conductive film 2 or tape is adhered to anelectrode (illustrated as 1a in FIG. 7) of the panel element 1. Themotors 217,218 function to move the panel member 1 in the X or Ydirections, respectively, relative to the peeling units 202,203.

Situated above the tables 200,201 are a pair of peeling units 202,203which are identical except for their orientation with respect to thepanel element 1. The peeling unit 202 is fixed on a support frame 219 bya plurality of bolts 220 and comprises a mounting member, or supportplate, 4 and a feed reel 5. The feed reel 5 is mounted to the mountingmember by a first shaft 6. An uptake reel 7 is mounted on a mountingmember 4 via a second shaft 8. The peeling unit 202 further comprises aphotoelectric sensor 11 which detects the presence of the peeling tape204. An elevating plate 15 extends from the mounting member 4. A peelingtape 204 is wound around the feed reel 5, runs past a cylinder 102 andthe photoelectric sensor 11, and over the elevating plate 15. Afterrunning over the elevating plate, the peeling tape 204 runs under a mainroller 14 and to the uptake reel 7. An ionizer 16 removes staticelectricity from the peeling tape 204 as it runs toward the uptake reel7.

As will be discussed below in detail, during operation of the peelingapparatus ! 10, the interlayer 3 is peeled away from sections from theanisotropic conductive film 2 which are positioned in the X-direction bythe peeling unit 202. Similarly, the interlayer 3 is peeled away fromsections of the anisotropic conductive film 2 which are positioned inthe Y-direction by the peeling unit 203.

Turning now to FIG. 2, a front view of the peeling unit 202 of a peelingapparatus 110 according to the present invention is illustrated. Asshown in FIG. 2, the peeling unit 202 is supported by a support frame219 via a plurality of the support bolts 220. The peeling tape 204having an adhesive surface 205 is wound around the feed reel 5 in theclockwise direction. The feed reel 5 is rotatably attached to themounting member 4 via the first shaft 6. The uptake reel 7 is rotatablyattached to the mounting member 4 via the second shaft 8 and takes upthe peeling tape 204 after running under the main roller 14. The peelingtape 2 runs from the feed reel 5 to the guide rollers 9,10 which guidethe peeling tape 204 past the photoelectric sensor 11 which recognizesthe presence of the peeling tape 204. The peeling tape 204 then runsover the elevating plate 15 to a subsidiary roller 12 which guides thepeeling tape 204 to the main roller 14. After running under the mainroller 14, the peeling tape 204 runs under a subsidiary roller 13 and tothe uptake reel 7.

The main roller 14 presses the adhesive surface 205 of the peeling tape204 against the interlayer (not shown). The main roller 14 and thesubsidiary rollers 12, 13 are rotatably supported on the elevating plate15. On the periphery of the main roller 14, an O-ring or rubber ring(not shown) is fitted in order to enhance adhesion between the adhesivesurface 205 of the peeling tape 204 and the interlayer (not shown). Theionizer 16 removes the static electricity generated by friction duringthe peeling off of the interlayer 3 from the anisotropic conductivelayer. The ionizer 16 is fixed on the mounting member 4 through abracket 17.

As shown in FIG. 2, the cylinder 102 moves the elevating plate 15 up anddown along a guide (not shown). The lower end portion of a rod 103 iscoupled with the upper part of the elevating plate 15. The cylinder 102is fixed on the mounting member 4 through a pair of brackets 104,105.

A drum 90 is fixed on the second shaft 8. A brake shoe 93 is positionedagainst the drum 90 and is connected to a cylinder 91 via a rod 92. Thecylinder 91 is supported on the mounting member 4 via a mounting bracket94. When the cylinder 91 is activated, the rod 92 is forced upward,likewise forcing the brake shoe 93 into the drum 90. This action brakesthe rotation of the second shaft 8 by causing the brake shoe 93 at theupper end of the rod 92 to contact the drum 90.

Turning to FIG. 3, a rear view of the peeling unit 202 shown in FIG. 2is illustrated. As shown in FIG. 3, the peeling unit 202 is supported onthe support frame 219 by the bolts 220. The feed reel 5 is shownrotatably mounted to the mounting member 4 by the first shaft 6. Theuptake reel 7 is shown rotatably attached to the mounting member 4 bythe second shaft 8. The brake shoe 93 is shown attached to the rod 92and the cylinder 91, which is mounted to the mounting member 4 via themounting bracket 94.

The cylinder 102 moves the elevating plate 15 up and down along a guide100. The rod 103 is coupled with the elevating plate 15 and the cylinder102 is fixed on the mounting member 4 through the pair of brackets104,105. The elevating plate 15 is slidably connected to the mountingmember 4 via a slidable coupler 101.

As shown in FIG. 3, the peeling tape 204 is wound around the feed reel 5and runs in the direction of the guide rollers 9,10. After passing aguide roller 9, the peeling tape 204 passes the photoelectric sensor 11.After passing a guide roller 10, the peeling tape 204 passes under thesubsidiary roller 12, the main roller 14 and the subsidiary roller 13,and then runs to the uptake reel 7.

A first pulley 207 is rotatively coupled with the first shaft 6. A slideclutch 213 is installed between the first pulley 207 and the first shaft6. A motor 211 is fixed to the mounting member 4 through a supportmember 212, and a drive pulley 206 is fixed on an output shaft (notshown). A second gear 82 is rotatably supported on the second shaft 8,and is engaged with a first gear 74. A pulley 209 is mounted on thefirst gear 74 and rotates together with the first gear 74. A slideclutch 215 is installed between the second gear 82 and the second shaft8. All of the pulleys 206,207,209 are drivably connected together via abelt 76.

Turning to FIG. 4, a cross-sectional view along line A--A of the peelingunit 202 shown in FIG. 2 is illustrated. The feed reel 5 is shownrotatably attached to the first shaft 6, and having wound therearoundthe peeling tape 204. The uptake reel 7 is shown rotatably attached tothe second shaft 8. A holder 61 is fixed on the mounting member 4, and abearing 62 is held inside. The first shaft 6 is rotatably supported onthe mounting member 4 by the bearing 62. A reel main body 5b of the feedreel 5 is fixed on a boss 5c. A plate 5a supports the side surface ofthe peeling tape 204, which is wound in the reel main body 5b. The firstpulley 207 is rotatively coupled with the first shaft 6 by a bearing 63,and the slide clutch 213 is installed between the first pulley 207 andthe first shaft 6. The motor 211 is fixed to the mounting member 4through the support member 212, and the drive pulley 206 is fixed on anoutput shaft 210.

A holder 71 is fixed on the mounting member 4, and a bearing 72 is heldinside. A shaft 73 is rotatably supported on the bearing 72. The firstgear 74 and the pulley 209 are fixed on the shaft 73, and rotatetogether with the shaft 73.

The second shaft 8, on which the uptake reel 7 is fixed, is rotatablysupported by a holder 81 having a bearing (not shown) held inside. Thesecond gear 82 is rotatably supported on the second shaft 8, and isengaged with the first gear 74. A coupling wheel 82a engaged withundulations of a flange 75 of the slide clutch 215 is extended from thesecond gear 82 to the left side. A boss 8c is fixed to the second shaft8, and a reel main body 7b of the uptake reel 7 is fixed on the boss 8c.A plate 7a supports the side surface of the peeling tape 204 taken up inthe reel main body 7b. The drum 90 is fixed on the second shaft 8, andthe cylinder 91 brakes, when desired, the rotation of the second shaft 8by causing the brake shoe 93 provided at the front end of the rod 92 tocontact with the drum 90.

As shown in FIG. 3, the pulleys 206,207,209 are coupled through the belt76. The first gear 74 and the second gear 82 are engaged with eachother, and when the motor 211 is driven, the pulleys 206,207,209, thefirst gear 74, and the second gear 82 are placed together into rotation.However, since the pulley 207 and the first shaft 6, and the second gear82 and the second shaft 8 are respectively coupled together rotatably,the torque of the motor 211 is transmitted to the first shaft 6 andsecond shaft 8 through the slide clutches 213,215, respectively. Themeans for applying tension to the peeling tape 204 is composed of themotor 211 and the slide clutches 213,215.

A flange 32 of the slide clutch 213 is coupled with the undulations of acoupling wheel 77 extended from the first pulley 207 to the left side.The flange 32 fits over a hub 31. The hub 31 is attached to the firstshaft 6 via a pin 6c. During use of the peeling apparatus 110, to ensurethat a proper torque is transmitted to the first shaft 6, the force of aspring 34 is adjusted by an adjusting nut 33. The slide clutch 215 issimilar in structure to that of the slide clutch 213 described above.

Turning to FIG. 5, a cross-sectional view along line B--B of the peelingunit 202 shown in FIG. 2 is shown. The cylinder 102 is mounted to themounting member 4 by the brackets 104,105. The cylinder 102 is capableof applying force in the downward direction through the rod 103 tophysically manipulate the elevating plate 15. The movement of theelevating plate 15 is restricted by the guide 100 and is slidablyconnected to the guide 100 by the slidable coupler 101. The subsidiaryroller 12 and the main roller 14 are shown extending frontward from theelevating plate 15, with the peeling tape 204 running under thesubsidiary roller 12 and the main roller 14.

Turning to FIG. 6, a magnified sectional view of part C in FIG. 4 isshown. As shown in FIG. 6, the pin 6c inserted in the first shaft (notshown) is coupled with a groove 31a provided in the hub 31. Therefore,the first shaft (not shown) and the hub 31 rotate together. A pluralityof friction plates 36 are inserted between the spring 34 and the flange32, and the flange 32 and the hub 31. By the force of the spring 34, thefriction plate 36 is pressed against the flange 32. As a result, torquefrom the first pulley (not shown) is transmitted through the flange 32to the hub 31, that is, to the first shaft (not shown).

Returning to FIG. 2, the peeling tape 204 is maintained in constanttension as follows. A torque in the direction of arrow N1 is transmittedto the first shaft 6, while a torque in the direction of arrow N2 istransmitted to the second shaft 8. That is, a torque that results in thepeeling tape 204 being wound around the uptake reel 7 is applied to theuptake reel 7 and the feed reel 5. Therefore, tensions in the directionof arrow N3 and arrow N4 are generated in the peeling tape 204. The gearratio of the first gear 74 and second gear 82 is selected to make therotating torque of the shaft 8 larger than that of the shaft 6, thusallowing the tape to run from the feed reel 5 to the uptake reel 7. Tostop the peeling tape 204 from running, the brake shoe 93 is pressedagainst the drum 90 to prevent the uptake reel 7 from rotating.

Turning in particular to FIGS. 7 and 8 (and generally to FIGS. 1 and 2),the operation of the peeling apparatus 110 of the invention isdescribed. When the peeling units 202,203 are in a waiting state, themotor (not shown) is driven with the brake shoe 93 kept in contact withthe drum 90, thus maintaining a tension on the peeling tape 204. Asshown in FIGS. 7 and 8, the peeling tape 204 is fed from the feed reel 5to pass under the subsidiary roller 12, the main roller 14, and then thesubsidiary roller 13. After passing under the subsidiary roller 13, thepeeling tape 204 runs to the uptake reel 7. As also shown in FIGS. 7 and8, when the peeling tape 204 is engaged to the anisotropic conductivefilm 2 of the panel element 1 via the movement of the elevating plate15, the peeling tape 204 contacts the front end surface of theinterlayer 3 on the anisotropic conductive film 2.

When the cylinder 102 is activated, the elevating plate 15 is moveddownwardly N5. As shown in FIG. 7, the elevating plate 15 is lowered,the main roller 14 applies pressure in the direction N5 to the peelingtape 204 so that the adhesive surface 205 of the peeling tape 204 ispressed to the right end portion of the interlayer 3. This produces anadherence between the adhesive surface 205 of the peeling tape 204 andthe upper surface of the interlayer 3.

FIG. 8 depicts the action of the peeling unit as the brake is releasedby separating the brake shoe 93 from the drum 90. As shown in FIG. 8,the table 200 is moved in a direction parallel to the interlayer 3 inthe direction toward the rear end of the cut section of the interlayer3. As the table 200 is moved, the peeling tape 204 similarly moves.Because the adhesive force between the peeling tape 204 and theinterlayer 3 is greater than the adhesive force between the interlayer 3and the anisotropic conductive film 2, the interlayer 3 adheres to thepeeling tape 204 instead of the anisotropic conductive film 2 when thetable 200 moves in the X-direction. The peeling tape 204 passing beneaththe main roller 14 is then pulled in the direction of arrow N6 by thetorque of the uptake reel 7.

In this way, the peeling tape 204 with the adhesive surface 205 exposedis supplied from the feed reel 5, and is taken up on the uptake reel 7with the interlayer 3 adhered to the adhesive surface 205. This resultsin exposing the sticky surface of the anisotropic conductive film 2which covers the electrode 1a. As mentioned above, the peeling apparatus110 of this embodiment peels off the interlayer 3 and takes up thepeeling tape 204 at the same time with the movement of the table 200.The ionizer 16 removes the static electricity caused by friction whenpeeling off the separator 3.

Similar to the above description, the peeling unit 203 removesinterlayers arranged along the Y axis of FIG. 1 with the movement of thetable 201 in the X-direction.

Variations on the embodiments described above are possible. For example,one alternative embodiment comprises, instead of tables 200,201 whichmove, the peeling units themselves move in the X and Y direction. Anadvantage of this embodiment is that interlayer in both the X and Ydirections can easily be removed simultaneously.

As another variation, when the interlayer 3 is arranged in a straightline as shown in FIG. 1, multiple interlayers 3, only the straight linecan be continuously peeled by a single operation, so that the timerequired for peeling process may be shortened.

As yet another variation, the separator may be adhesively secured to asurface of any element, such as when a protective cover is formed by theseparator, as required. In the same manner, as described above, theseparator may be removed to expose the surface of the element.

Thus, as described above, the present invention obtains the above listedadvantages by providing an apparatus and method to supersede the manualstep for removal of an interlayer (or separator) from an anisotropicconductive tape used to bind an integrated driver circuit to theelectrode of a panel. As described, high precision of control can bereadily introduced into the manufacture of such integrated drivercircuits.

Of course, it should be understood that a wide range of changes andmodifications can be made to the preferred embodiment described above.It is therefore intended that from the foregoing detailed description itbe understood that it is the following claims, including allequivalents, which are intended to define the scope of the invention.

What is claimed is:
 1. A method for peeling an interlayer of a two-sidedadhesive tape adhered to an electrode of a panel element, comprising thesteps of:using a roller to press an adhesive surface of a peeling tapeonto one end of the interlayer on the two-sided adhesive tape so thatthe peeling tape adheres to the interlayer; and simultaneously (a)moving the roller toward a second end of the interlayer while pressingand adhering the peeling tape onto the interlayer and (b) peeling thepeeling tape from the two-sided adhesive tape such that the interlayerthat is adhered to the peeling tape is taken up by an uptake reel. 2.The method of peeling the interlayer of a two-sided adhesive tape ofclaim 1, wherein the two-side adhesive tape is an anisotropic conductivefilm.
 3. The method of peeling the interlayer of a two-sided adhesivetape of claim 1, wherein said panel element is a liquid crystal panel.4. A peeling method of separator of claim 1, wherein the two-sideadhesive tape is an anisotropic conductive film.
 5. A peeling method ofseparator of claim 1, wherein the element is a liquid crystal panel. 6.A method for peeling a separator on an adhesive tape adhered on asubstrate, comprising the steps of:using a roller to press an adhesivesurface of a peeling tape onto one end of the separator on the adhesivetape so that the peeling tape adheres to the separator; simultaneously(a) moving the roller toward a second end of the separator whilepressing and adhering the peeling tape onto the separator and (b)peeling the peeling tape from the adhesive tape such that the separatoradhered to the peeling tape is taken up by an uptake reel.